Semiconductor device with contact plug

ABSTRACT

The semiconductor device includes a substrate, an epi-layer, a first etch stop layer, an interlayer dielectric (ILD) layer, a second etch stop layer, a protective layer, a liner, a silicide cap and a contact plug. The substrate has a first portion and a second portion. The epi-layer is disposed in the first portion. The first etch stop layer is disposed on the second portion. The ILD layer is disposed on the first etch stop layer. The second etch stop layer is disposed on the ILD layer, in which the first etch stop layer, the ILD layer and the second etch stop layer form a sidewall surrounding the first portion. The protective layer is disposed on the sidewall. The liner is disposed on the protective layer. The silicide cap is disposed on the epi-layer. The contact plug is disposed on the silicide cap and surrounded by the liner.

PRIORITY CLAIM AND CROSS-REFERENCE

This is a divisional application of U.S. patent application Ser. No.14/477,689 filed on Sep. 4, 2014, now U.S. Pat. No. 9,887,129 issued onFeb. 6, 2018, which is incorporated herein by reference in its entirety.

BACKGROUND

As integration of elements in integrated circuits (IC) increases, linewidths and geometries for semiconductor devices are reduced.Accordingly, resistance of a gate and a source/drain region of a MOStransistor made by conventional techniques are relatively high. Inconventional techniques, an interlayer dielectric (ILD) layer and anetch stop layer are formed on a patterned substrate for isolation andover-etching. Then, the ILD layer and the etch stop layer are etchedusing an etchant to form an opening (surrounded by a sidewall of the ILDlayer and the etch stop layer) for exposing a contact area such as thesource/drain region, and a metal silicide layer can be formed on thecontact area through the opening for reducing the resistance.

In the operation of forming the metal silicide layer, the opening isrequired to be cleaned first. In conventional techniques, a liner isformed conformal to the opening, and then a sputter etching operation(such as using an inert gas) and an SPM (Sulfuric Acid-Hydrogen PeroxideMixture) operation (such as using H₂SO₄ and H₂O₂ solution) are performedin sequence. The liner protects the sidewall from being damaged by thesputter etching operation and the SPM operation. However, the liner isnot perfectly adhesive to the sidewall and has a poor surface, such thatan interface between the ILD layer and the etch stop layer is etched bythe H₂SO₄ and H₂O₂ solution at SPM operation. In some conditions, ametal gate (MG) of the patterned substrate is also partially or entirelyremoved (which is also referred to as MG missing) by the H₂SO₄ and H₂O₂solution etching, thus impacting the IC performance and yield.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a schematic cross-sectional diagram of a semiconductor devicein accordance with some embodiments of the present disclosure.

FIG. 2 is a schematic cross-sectional diagram of a semiconductor devicein accordance with certain embodiments of the present disclosure.

FIG. 3A to FIG. 3P are schematic cross-sectional views of intermediatestages showing a method for fabricating a semiconductor device inaccordance with some embodiments of the present disclosure.

FIG. 4A to FIG. 4J are schematic cross-sectional views of intermediatestages showing a method for fabricating a semiconductor device inaccordance with certain embodiments of the present disclosure.

FIG. 5 is a flow chart of a method for fabricating a semiconductordevice in accordance with some embodiments of the present disclosure.

FIG. 6 is a flow chart of a method for fabricating a semiconductordevice in accordance with various embodiments of the present disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “above” and the like, may beused herein for ease of description to describe one element or feature'srelationship to another element(s) or feature(s) as illustrated in thefigures. The spatially relative terms are intended to encompassdifferent orientations of the device in use or operation in addition tothe orientation depicted in the figures. The apparatus may be otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein may likewise be interpretedaccordingly.

Embodiments of the present disclosure are directed to a semiconductordevice (such as a signal device or a logic device) with a protectivelayer between a liner and a sidewall in an opening. The protective layeris formed from silicon oxide or silicon nitride for enhancing anadhesive effect between the liner and the sidewall, thereby preventingMG missing from occurring.

In various embodiments of the present disclosure, a method forfabricating a semiconductor device (such as a signal device or a logicdevice) is provided to prevent a metal gate of a patterned substratefrom missing at SPM operation.

FIG. 1 is a schematic cross-sectional diagram of a semiconductor device100 in accordance with some embodiments of the present disclosure. FIG.1 has been simplified for the sake of clarity to better understand theinventive concepts of the present disclosure. The semiconductor device100 may include memory cells and/or logic circuits; passive componentssuch as resistors, capacitors, inductors, and/or fuses; activecomponents, such as metal-oxide-semiconductor field effect transistors(MOSFETs), complementary metal-oxide-semiconductor transistors (CMOSs),p-channel metal-oxide-semiconductor field effect transistors (PFETs),n-channel metal-oxide-semiconductor field effect transistor (NFETs),high voltage transistors, and/or high frequency transistors; othersuitable components; or combinations thereof. Additional features can beadded in the semiconductor device 100, and some of the featuresdescribed below can be replaced or eliminated for additional embodimentsof the semiconductor device 100.

In FIG. 1, the semiconductor device 100 includes a substrate 110, anepi-layer 120, a first etch stop layer 130, an interlayer dielectric(ILD) layer 140, a second etch stop layer 150, a protective layer 160, aliner 170, a silicide cap 180 and a contact plug 190. In someembodiments, the substrate 110 is a semiconductor substrate includingsilicon. The substrate 110 may be a p-type or n-type substrate.Alternatively or additionally, the substrate 110 includes anotherelementary semiconductor, such as germanium; a compound semiconductorincluding silicon carbide, gallium arsenic, gallium phosphide, indiumphosphide, indium arsenide, and/or indium antimonide; an alloysemiconductor including SiGe, GaAsP, AlInAs, AlGaAs, GaInAs, GaInP,and/or GaInAsP; or combinations thereof. In certain embodiments, thesubstrate 110 is a semiconductor on insulator (SOI). In alternativeembodiments, the substrate 110 may include a doped epi layer, a gradientsemiconductor layer, and/or a semiconductor layer overlying anothersemiconductor layer of a different type, such as a silicon layer on asilicon germanium layer. The substrate 110 may include various dopedregions depending on design requirements of the semiconductor device 100(e.g., p-type wells or n-type wells). The doped regions may be dopedwith p-type dopants, such as boron or BF₂; n-type dopants, such asphosphorus or arsenic; or a combination thereof. The doped regions maybe disposed directly on the substrate 110, in a P-well structure, in aN-well structure, in a dual-well structure, or using a raised structure.In some embodiments, the substrate 110 has a first portion 110A and asecond portion 110B adjacent to the first portion 110A.

The epi-layer 120 formed from such as silicon or silicon-germanium, isdisposed in the first portion 110A of the substrate 110. In someembodiments, an epitaxy or epitaxial (epi) process may be used to formthe epi-layer 120. The epi process may include a selective epitaxygrowth (SEG) process, CVD deposition techniques (e.g., vapor-phaseepitaxy (VPE) and/or ultra-high vacuum CVD (UHV-CVD)), molecular beamepitaxy, other suitable epi processes, or combinations thereof. The epiprocess may use gaseous and/or liquid precursors, which may interactwith the composition of the substrate 110. The deposited semiconductormaterial provides stress or strain to the channel regions of thesemiconductor device 100 to enhance carrier mobility of the device andenhance device performance. In the depicted embodiment, silicongermanium (SiGe) is deposited by an epi process to form a SiGe sourceand drain feature. The epi-layer 120 may be doped with a suitabledopant, such as boron (B). Alternatively, the source and drain featureis silicon (Si) source and drain features, which may be doped with asuitable dopant, such as carbon (C). The epi-layer 120 may be in-situdoped or undoped during the epi process, and then doped in a subsequentprocess. The doping may be achieved by an ion implantation process,plasma immersion ion implantation (PIII) process, gas and/or solidsource diffusion process, other suitable process, or combinationsthereof. The epi-layer 120 may further be exposed to an annealingprocess, such as a rapid thermal annealing process.

In some embodiments, an isolation feature 121 is disposed in the secondregion 110B of the substrate 110 to isolate various regions of thesubstrate 110. For example, the isolation feature 121 defines activeregions of the semiconductor device 100 in the substrate 110, in whichvarious semiconductor devices (such as transistor devices) are disposedtherein. The defined active regions may be referred to as oxide-definedactive regions (put another way, OD regions of the semiconductor device100). The isolation feature 121 utilizes isolation technology, such aslocal oxidation of silicon (LOCOS) and/or shallow trench isolation(STI), to define and electrically isolate the various regions. Theisolation feature 121 includes silicon oxide, silicon nitride, siliconoxynitride, other suitable materials, or combinations thereof. In someembodiments, an STI is formed by the operations including aphotolithography process, etching a trench in the substrate (forexample, by using a dry etching, wet etching, or combinations thereof),and filling the trench (for example, by using a chemical vapordeposition process) with one or more dielectric materials. For example,the filled trench may have a multi-layer structure, such as a thermaloxide liner layer filled with silicon nitride or silicon oxide. Incertain embodiments, the STI structure may be created using a processingsequence such as: growing a pad oxide, forming a low pressure chemicalvapor deposition (LPCVD) nitride layer over the pad oxide, patterning anSTI opening in the pad oxide and nitride layer using photoresist andmasking, etching a trench in the substrate in the STI opening,optionally growing a thermal oxide trench liner to improve the trenchinterface, filling the trench with oxide, using chemical mechanicalpolishing (CMP) processing to etch back and planarize, and using anitride stripping process to remove the nitride layer.

Various gate structures 122 are disposed over the substrate 110. In someembodiments, the gate structures 122 are formed by deposition processes,lithography patterning processes, etching processes, or a combinationthereof. The deposition processes include chemical vapor deposition(CVD), physical vapor deposition (PVD), atomic layer deposition (ALD),high density plasma CVD (HDPCVD), metal organic CVD (MOCVD), remoteplasma CVD (RPCVD), plasma enhanced CVD (PECVD), plating, other suitabledeposition methods, or combinations thereof. The lithography patterningprocesses include resist coating (such as spin-on coating), soft baking,mask aligning, exposure, post-exposure baking, developing the resist,rinsing, drying (such as hard baking), other suitable processes, orcombinations thereof. Alternatively, the lithography exposing process isimplemented or replaced by other proper methods, such as masklessphotolithography, electron-beam writing, or ion-beam writing. Theetching processes include dry etching, wet etching, other etchingmethods, or combinations thereof.

In the depicted embodiment, each of the gate structures 122 includes agate dielectric layer 122A, a metal gate 122B, a spacer liner 122C, anda spacer 122D. The gate dielectric layer 122A and the metal gate 122Bform a gate stack of the gate structures 122. The gate stack may includeadditional layers depending on design requirements of the semiconductordevice 100. The gate dielectric layer 122A is disposed over thesubstrate 110 for the gate structures 122. The gate dielectric layer122A includes a dielectric material, such as silicon oxide, siliconoxynitride, silicon nitride, a high-k dielectric material, othersuitable dielectric material, or combinations thereof. Exemplary high-kdielectric materials include HfO₂, HfSiO, HfSiON, HfTaO, HfTiO, HfZrO,Ta₂O₅, TiO₂, Al₂O₃, ZrO₂, Y₂O₃, L₂O₃, other suitable materials, orcombinations thereof. The gate dielectric layer 122A may include amultilayer structure. For example, the gate dielectric layer 122A mayinclude an interfacial layer, and a high-k dielectric material layerformed on the interfacial layer. An exemplary interfacial layer may be agrown silicon oxide layer formed by a thermal process or ALD process.

The metal gate 122B is disposed over the gate dielectric layer 122A. Inthe depicted embodiment, the metal gate 122B is a polycrystallinesilicon (polysilicon) layer. The polysilicon layer may be doped forproper conductivity. Alternatively, the polysilicon is not necessarilydoped if a dummy gate is to be formed and replaced in a subsequent gatereplacement process. Alternatively, the metal gate 122B includes aconductive layer having a proper work function, and therefore, the metalgate 122B can also be referred to as a work function layer. The workfunction layer includes any suitable material, such that the layer canbe tuned to have a proper work function for enhanced performance of theassociated device. For example, if a p-type work function metal(p-metal) for a PFET device is desired, the conductive layer may includeTiN or TaN. On the other hand, if an n-type work function metal(n-metal) for an NFET device is desired, the conductive layer mayinclude Ta, TiAl, TiAlN, or TaCN. The work function layer may includedoped conducting oxide materials. The metal gate 122B may include otherconductive materials, such as aluminum, copper, tungsten, metal alloys,metal silicide, other suitable materials, or combinations thereof.

The spacer liner 122C and the spacer 122D are disposed along sidewallsof the gate stack of the gate structures 122 (such as along sidewalls ofthe gate dielectric layer 122A and the metal gate 122B). In the depictedembodiment, the spacer liner 122C includes an oxide material, such assilicon oxide, and the spacer 122D includes a nitride material, such assilicon nitride. Alternatively, the spacer 122D includes anothersuitable dielectric material, such as silicon oxide, silicon oxynitride,or combinations thereof. The spacer liner 122C may also include anothersuitable dielectric material. The spacer liner 122C and the spacer 122Dare formed by a suitable process. For example, the spacer liner 122C andthe spacer 122D are formed by blanket depositing a first dielectriclayer (a silicon oxide layer) over the semiconductor device 100 and asecond dielectric layer (a silicon nitride layer) over the firstdielectric layer, and then, anisotropically etching to remove thedielectric layers to form the spacer liner 122C and the spacer 122D asillustrated in FIG. 1.

The semiconductor device 100 may include additional features that arenot illustrated. For example, lightly doped source/drain (LDD) regionsand/or heavily doped source/drain (HDD) regions may be formed by ionimplantation or diffusion of n-type dopants, such as phosphorous orarsenic, or p-type dopants, such as boron. The LDD and/or HDD regionsmay be interposed by the respective gate structures 122.

The first etch stop layer 130 is disposed on the second portion 110B ofthe substrate 110 for preventing problems caused by contactmisalignment. In some embodiments, the first etch stop layer 130 may beformed from commonly used materials including, but not limited to, SiNx,SiOx, SiON, SiC, SiCN, BN, SiBN, SiCBN, and combinations thereof. Inalternative embodiments, the first etch stop layer 130 is formed usingplasma enhanced chemical vapor deposition (PECVD), although othermethods such as sub atmospheric chemical vapor deposition (SACVD), lowpressure chemical vapor deposition (LPCVD), atomic layer deposition(ALD), high-density plasma (HDP), plasma enhanced atomic layerdeposition (PEALD), molecular layer deposition (MLD), plasma impulsechemical vapor deposition (PICVD), and the like can also be used.

The interlayer (or inter-level) dielectric (ILD) layer 140 formed from adielectric layer, for example, is disposed on the first etch stop layer130. The ILD layer 140 includes a dielectric material, such as siliconoxide, silicon nitride, silicon oxynitride, low-k dielectric material,other suitable dielectric materials, or combinations thereof. Exemplarylow-k dielectric materials include fluorinated silica glass (FSG),carbon doped silicon oxide, Black Diamond® (Applied Materials of SantaClara, Calif.), Xerogel, Aerogel, amorphous fluorinated carbon,Parylene, BCB (bis-benzocyclobutenes), SiLK (Dow Chemical, Midland,Mich.), polyimide, other proper materials, or combinations thereof. TheILD layer 140 may include a multilayer structure having multipledielectric materials, and additional layers may be disposed overlyingand/or underlying the ILD layer 140. A chemical mechanical polishing(CMP) process of the ILD layer 140 may be performed until the metal gate122B of the gate structures 122 is exposed as illustrated in FIG. 1.

The second etch stop layer 150 is disposed on the ILD layer 140 forpreventing problems caused by contact misalignment. In some embodiments,the second etch stop layer 150 may be formed from commonly usedmaterials including, but not limited to, SiNx, SiOx, SiON, SiC, SiCN,BN, SiBN, SiCBN, and combinations thereof. In alternative embodiments,the second etch stop layer 150 is formed using plasma enhanced chemicalvapor deposition (PECVD), although other methods such as sub atmosphericchemical vapor deposition (SACVD), low pressure chemical vapordeposition (LPCVD), atomic layer deposition (ALD), high-density plasma(HDP), plasma enhanced atomic layer deposition (PEALD), molecular layerdeposition (MLD), plasma impulse chemical vapor deposition (PICVD), andthe like can also be used. In some embodiments, an inter-metaldielectric layer 152 is disposed on the second etch stop layer 150.

Further, the first etch stop layer 130, the ILD layer 140 and the secondetch stop layer 150 form a sidewall 151 surrounding the first portion110A. The protective layer 160 is disposed on the sidewall 151, in whichthe protective layer 160 is formed from oxide or nitride. In someembodiments, the protective layer 160 is formed from silicon oxide orsilicon nitride. In certain embodiments, the protective layer 160 isformed using a chemical vapor deposition (CVD) process, a physical vapordeposition (PVD) process or a high density plasma (HDP) process. In someembodiments, the protective layer 160 has a thickness in a range fromabout 1 nm to about 1.8 nm, and the opening has a size in a range fromabout 15 nm to about 21 nm. In certain embodiments, a ratio of thethickness to the size is in a range from about 0.04 to 0.12. The effectof the protective layer 160 will be described later.

The liner 170 is disposed on the protective layer 160. In someembodiments, the liner 170 is formed from silicon nitride, siliconoxy-nitride, silicon carbide or silicon oxy-carbide. In certainembodiments, the protective layer 160 formed from oxide or nitride maybe used for enhancing an adhesive effect between the sidewall 151 andthe liner 170, thereby preventing the metal gate 122B from being etchedwhen a SPM operation is performed, thus preventing the MG missing causedby the SPM operation. In alternative embodiments, the protective layer160 itself may also be used to protect the metal gate 122B from beingetched when the SPM operation is performed, thus preventing the MGmissing caused by the SPM operation. Therefore, the IC performance andyield are improved.

The silicide cap 180 is disposed on the epi-layer 120. In someembodiments, the silicide cap 180 is formed from titanium silicide,nickel silicide, cobalt silicide, platinum silicide, palladium silicide,tungsten silicide, tantalum silicide or erbium silicide. In alternativeembodiments, the silicide cap 180 is formed by the operation of forminga metal layer (not shown) on the epi-layer 120 and then annealing themetal layer. The operation of forming the metal layer on the epi-layer120 may be performed using a chemical vapor deposition (CVD) process, aphysical vapor deposition (PVD) process or a high density plasma (HDP)process.

The contact plug 190 is disposed on the silicide cap 180 and issurrounded by the liner 170, such that the contact plug 190 iselectrically connected to the epi-layer 120 via the silicide cap 180. Insome embodiments, the contact plug 190 includes aluminum (Al), tungsten(W), or copper (Cu), etc. In alternative embodiments, the contact plug190 is formed using a CVD process.

FIG. 2 is a schematic cross-sectional diagram of a semiconductor device200 in accordance with certain embodiments of the present disclosure. Asshown in FIG. 2, the semiconductor device 200 includes a substrate 210,an epi-layer 220, a dielectric layer 230, an inter-metal dielectriclayer 234, a protective layer 240, a liner 250, a silicide cap 260 and acontact plug 270. In some embodiments, the substrate 210, the epi-layer220, the inter-metal dielectric layer 234, the protective layer 240, theliner 250, the silicide cap 260 and the contact plug 270 may be formedfrom the materials similar to the materials forming the silicon-basedsubstrate 110, the epi-layer 120, the inter-metal dielectric layer 152,the protective layer 160, the liner 170, the silicide cap 180 and thecontact plug 190, respectively. The dielectric layer 230 may include afirst etch stop layer 231, an interlayer dielectric (ILD) layer 232, asecond etch stop layer 233. In some embodiments, the first etch stoplayer 231, the interlayer dielectric (ILD) layer 232, and the secondetch stop layer 233 may be formed from the materials similar to thematerials forming the first etch stop layer 130, the interlayerdielectric (ILD) layer 140, the second etch stop layer 150.

FIG. 3A to FIG. 3P are schematic cross-sectional views of intermediatestages showing a method for fabricating a semiconductor device 300 inaccordance with some embodiments of the present disclosure. As shown inFIG. 3A, a substrate 310 is provided, in which the substrate has a firstportion 310A and a second portion 310B adjacent to the first portion310A. In some embodiments, the substrate 310 may be formed from thematerials similar to the materials forming the substrate 110.

As shown in FIG. 3B, an epi-layer 320 is formed in the first portion310A. In some embodiments, the epi-layer 320 may be formed from thematerials similar to the materials forming the epi-layer 120. In certainembodiments, the epi-layer 320 may be formed using the processes similarto the processes forming the epi-layer 120.

As shown in FIG. 3C, an isolation feature 321 is formed in the secondportion 310B. In some embodiments, the isolation feature 321 may beformed from the materials similar to the materials forming the isolationfeature 121. In certain embodiments, the isolation feature 321 may beformed using the processes similar to the processes forming theisolation feature 121.

As shown in FIG. 3D, various gate structures 322 are formed on thesecond regions 122B of the substrate 310. Each of the gate structures322 includes a gate dielectric layer 322A, a metal gate 322B, a spacerliner 322C, and a spacer 322D. In some embodiments, the gate dielectriclayer 322A, the metal gate 322B, the spacer liner 322C, and the spacer322D may be formed from the materials similar to the materials formingthe gate dielectric layer 122A, the metal gate 122B, the spacer liner122C, and the spacer 122D, respectively. In certain embodiments, thegate dielectric layer 322A, the metal gate 322B, the spacer liner 322C,and the spacer 322D may be formed using the processes similar to theprocesses forming the gate dielectric layer 122A, the metal gate 122B,the spacer liner 122C, and the spacer 122D, respectively.

As shown in FIG. 3E, a first etch stop layer 330 is formed on the secondportion 310B and the epi-layer 320. In some embodiments, the first etchstop layer 330 may be formed from the materials similar to the materialsforming first etch stop layer 130. In certain embodiments, the firstetch stop layer 330 may be formed using the processes similar to theprocesses forming the first etch stop layer 130.

As shown in FIG. 3F, an interlayer dielectric (ILD) layer 340 is formedon the first etch stop layer 330. In some embodiments, the interlayerdielectric (ILD) layer 340 may be formed from the materials similar tothe materials forming the interlayer dielectric (ILD) layer 140. Incertain embodiments, the interlayer dielectric (ILD) layer 340 may beformed using the processes similar to the processes forming theinterlayer dielectric (ILD) layer 140. In some embodiments, a chemicalmechanical polishing (CMP) process may be performed on the interlayerdielectric (ILD) layer 340 and the first etch stop layer 330 to exposethe metal gate 322, as shown in FIG. 3G.

As shown in FIG. 3H, a second etch stop layer 350 is formed on the ILDlayer 340 to cover the metal gate 322. In some embodiments, the secondetch stop layer 350 may be formed from the material similar to thatforming the second etch stop layer 150. In certain embodiments, thesecond etch stop layer 350 may be formed using the processes similar tothe processes forming the second etch stop layer 150.

As shown in FIG. 3I, an inter-metal dielectric layer 352 is formed onthe second etch stop layer 350. In some embodiments, the inter-metaldielectric layer 352 may be formed from the materials similar to thematerials forming the inter-metal dielectric layer 152. In certainembodiments, the inter-metal dielectric layer 352 may be formed usingthe processes similar to the processes forming the inter-metaldielectric layer 152.

As shown in FIG. 3J, a portion of the first etch stop layer 330, aportion of the ILD layer 340 and a portion the second etch stop layer350 on the first portion 310A are etched to form an opening 353, inwhich the remaining portion of the first etch stop layer 330, theremaining portion of the ILD layer 340 and the remaining portion of thesecond etch stop layer 350 form a sidewall 351 of the opening 353. Insome embodiments, the portion of the first etch stop layer 330, theportion of the ILD layer 340 and the portion of the second etch stoplayer 350 may be etched using a dry etching process or a wet etchingprocess.

As shown in FIG. 3K, a protective layer 360 is deposited on the sidewall351 and the epi-layer 320, in which the protective layer 360 is formedfrom oxide or nitride. In some embodiments, the protective layer 360 maybe formed from the materials similar to the materials forming theprotective layer 160. In certain embodiments, the protective layer 360may be formed using the processes similar to the processes forming theprotective layer 160.

As shown in FIG. 3L, a liner 370 is formed on the protective layer 360.In some embodiments, the liner 370 may be formed from the materialssimilar to the materials forming the liner 170.

As shown in FIG. 3M, a sputter etching operation 371 is performed toremove a portion of the protective layer 360 and a portion of the liner370 on the epi-layer 320. In some embodiments, the sputter etchingoperation 371 is performed using an inert gas such as argon. As shown inFIG. 3M and FIG. 3N, the opening 353 is cleaned using an SPM solution373 for removing remaining impurities 372 produced from the sputteretching operation 371, in which the SPM solution 373 includes H₂SO₄ andH₂O₂. In some embodiments, the protective layer 360 formed from oxide ornitride may be used for enhancing an adhesive effect between thesidewall 351 and the liner 370, thereby preventing the metal gate 322Bfrom being etched at the SPM operation, thus preventing the MG missingcaused by the SPM operation. In alternative embodiments, the protectivelayer 360 itself may be also used to protect the metal gate 322B frombeing etched when the SPM operation is performed, thus preventing the MGmissing caused by the SPM operation. Therefore, the IC performance andyield are improved.

As shown in FIG. 3O, a silicide cap 380 is formed on the epi-layer 320.In some embodiments, the silicide cap 380 may be formed from thematerials similar to the materials forming the silicide cap 180. In someembodiments, the silicide cap 380 may be formed by forming a metal layer(not shown) conformal to the opening 353 and above the second etch stoplayer 350 first. The metal layer is formed from titanium, nickel,cobalt, platinum, palladium, tungsten, tantalum or erbium. In certainembodiments, the metal layer is formed using a CVD process, a PVDprocess or a HDP process. Then, the metal layer is annealed to form thesilicide cap 380 on the epi-layer 320 and a silicide layer (not shown)above the second etch stop layer 350. Thereafter, the silicide layer isremoved such as using a chemical mechanical polishing (CMP) process.

As shown in FIG. 3P, a contact plug 390 fills the opening 353. In someembodiments, the contact plug 390 may be formed from the materialsimilar to that forming the contact plug 190.

FIG. 4A to 4J are schematic cross-sectional views of intermediate stagesshowing a method for fabricating a semiconductor device 400 inaccordance with certain embodiments of the present disclosure. As shownin FIG. 4A, a substrate 410 is provided. In some embodiments, thesubstrate 410 may be formed from the materials similar to the materialsforming the substrate 110.

As shown in FIG. 4B, an epi-layer 420 is formed in the substrate 410. Insome embodiments, the epi-layer 420 may be formed from the materialsimilar to that forming the epi-layer 120. In certain embodiments, theepi-layer 420 may be formed using the processes similar to those formingthe epi-layer 120.

As shown in FIG. 4C, a dielectric layer 430 is formed on the substrate410. In some embodiments, the dielectric layer 430 is a multi-layerwhich is formed by depositing a first etch stop layer 431, an ILD layer432 and a second etch stop layer 433 on the substrate 410 sequentially.In some embodiments, the first etch stop layer 431, the ILD layer 432and the second etch stop layer 433 may be formed from the materialssimilar to the materials forming the first etch stop layer 131, the ILDlayer 132 and the second etch stop layer 133. In certain embodiments,the first etch stop layer 431, the ILD layer 432 and the second etchstop layer 433 may be formed using the processes similar to theprocesses forming the first etch stop layer 131, the ILD layer 132 andthe second etch stop layer 133. In alternative embodiments, aninter-metal dielectric layer 434 is disposed on the second etch stoplayer 433.

As shown in FIG. 4D, a portion of the dielectric layer 430 is etched toform an opening 435. The opening 435 has a bottom 435A and a sidewall435B surrounding the bottom 435A. In some embodiments, the portion ofthe dielectric layer 430 may be etched using a dry etching process or awet etching process.

As shown in FIG. 4E, a protective layer 440 is deposited on the sidewall435B and the bottom 435A, in which the protective layer 440 is formedfrom oxide or nitride. In some embodiments, the protective layer 440 isdeposited using a CVD process, a PVD process or a HDP process.

As shown in FIG. 4F, a liner 450 is formed on the protective layer 440.In some embodiments, the liner 450 may be formed from the materialsimilar to that forming the liner 170.

As shown in FIG. 4G, a sputter etching operation 451 is performed toremove the protective layer 440 and the liner 450 on the bottom 435A. Insome embodiments, the sputter etching operation 451 is performed usingan inert gas such as argon. As shown in FIG. 4G and FIG. 4H, the opening435 is cleaned using an SPM solution 453 for removing remainingimpurities 452 produced from the sputter etching operation 451, in whichthe SPM solution 453 includes H₂SO₄ and H₂O₂. In some embodiments, theprotective layer 440 formed from oxide or nitride may be used forenhancing an adhesive effect between the sidewall 435B and the liner450, thereby preventing the dielectric layer 430 from being etched atthe SPM operation.

As shown in FIG. 4I, a silicide cap 460 is formed on the bottom 435A. Insome embodiments, the silicide cap 460 may be formed from the materialssimilar to the materials forming the silicide cap 180. In someembodiments, the silicide cap 460 may be formed by forming a metal layer(not shown) conformal to the opening 435 and above the second etch stoplayer 433 first. The metal layer is formed from titanium, nickel,cobalt, platinum, palladium, tungsten, tantalum or erbium. In certainembodiments, the metal layer is formed using a CVD process, a PVDprocess or a HDP process. Then, the metal layer is annealed to form thesilicide cap 460 on the bottom 435A and a silicide layer (not shown)above the second etch stop layer 433. Thereafter, the silicide layer isremoved such as using a chemical mechanical polishing (CMP) process.

As shown in FIG. 4J, the opening 435 is filled with a contact plug 470.In some embodiments, the contact plug 470 may be formed from thematerials similar to the materials forming the contact plug 190.

Referring to FIG. 5 together with FIG. 3A, FIG. 3B, FIG. 3E, FIG. 3F,FIG. 3H and FIG. 3J to FIG. 3P, FIG. 5 is a flow chart of a method 500for fabricating a semiconductor device 300 in accordance with someembodiments of the present disclosure. The method 500 begins atoperation 502, where a substrate 310 with a first portion 310A and asecond portion 310B adjacent to the first portion 310A is provided, asshown in FIG. 3A. At operation 504, an epi-layer 320 is formed in thefirst portion 310A, as shown in FIG. 3B. At operation 506, a first etchstop layer 330 is formed on the second portion 310B and the epi-layer320, as shown in FIG. 3E. At operation 508, an interlayer dielectric(ILD) layer 340 is formed on the first etch stop layer 330, as shown inFIG. 3F. At operation 510, a second etch stop layer 350 is formed on theILD layer 340, as shown in FIG. 3H. At operation 512, a portion of thefirst etch stop layer 330, a portion of the ILD layer 340 and a portionof the second etch stop layer 350 are etched to form an opening 353 onthe first portion 310A, in which the remaining portion of the first etchstop layer 330, the remaining portion of the ILD layer 340 and theportion of the remaining second etch stop layer 350 form a sidewall 351of the opening 353, as shown in FIG. 3J. At operation 514, a protectivelayer 360 is deposited on the sidewall 351 and the epi-layer 320, inwhich the protective layer 360 is formed from oxide or nitride, as shownin FIG. 3K. At operation 516, a liner 370 is formed on the protectivelayer 360, as shown in FIG. 3L. At operation 518, a sputter etchingoperation 371 is performed to remove a portion of the protective layer360 and a portion of the liner 370 on the epi-layer 320, as shown inFIG. 3M. At operation 520, the opening 353 is cleaned using an SPMsolution 373, in which the SPM solution 373 includes H₂SO₄ and H₂O₂, asshown in FIG. 3N. At operation 522, a silicide cap 380 is formed on theepi-layer 320, as shown in FIG. 3O. At operation 524, the opening 353 isfilled with a contact plug 390, as shown in FIG. 3P.

Referring to FIG. 6 together with FIG. 4A and FIG. 4C to 4H, FIG. 6 is aflow chart of a method 600 for fabricating a semiconductor device 400 inaccordance with various embodiments of the present disclosure. Themethod 600 begins at operation 602, where a substrate 410 is provided,as shown in FIG. 4A. At operation 604, a dielectric layer 430 is formedon the substrate 410, as shown in FIG. 4C. At operation 606, a portionof the dielectric layer 430 is etched to form an opening 435, in whichthe opening 435 has a bottom 435A and a sidewall 435B surrounding thebottom 435A, as shown in FIG. 4D. At operation 608, a protective layer440 is deposited on the sidewall 435B and the bottom 435A, in which theprotective layer 440 is formed from oxide or nitride, as shown in FIG.4E. At operation 610, a liner 450 is formed on the protective layer 440,as shown in FIG. 4F. At operation 610, a sputter etching operation 451is performed to remove the protective layer 440 and the liner 450 on thebottom 435A, as shown in FIG. 4G. At operation 612, the opening 435 iscleaned using an SPM solution 453, in which the SPM solution 453includes H₂SO₄ and H₂O₂, as shown in FIG. 4H.

In accordance with some embodiments, the present disclosure discloses asemiconductor device. The semiconductor device includes a substrate, anepi-layer, a first etch stop layer, an interlayer dielectric (ILD)layer, a second etch stop layer, a protective layer, a liner, a silicidecap and a contact plug. The substrate has a first portion and a secondportion adjacent to the first portion. The epi-layer is disposed in thefirst portion. The first etch stop layer is disposed on the secondportion. The interlayer dielectric (ILD) layer is disposed on the firstetch stop layer. The second etch stop layer is disposed on the ILDlayer, in which the first etch stop layer, the ILD layer and the secondetch stop layer form a sidewall surrounding the first portion. Theprotective layer is disposed on the sidewall, in which the protectivelayer is formed from oxide or nitride. The liner is disposed on theprotective layer. The silicide cap is disposed on the epi-layer. Thecontact plug is disposed on the silicide cap and surrounded by theliner.

In accordance with certain embodiments, the present disclosure disclosesa method for forming a semiconductor device. In this method, a substratewith a first portion and a second portion adjacent to the first portionis provided. An epi-layer is formed in the first portion. A first etchstop layer is formed on the second portion and the epi-layer. Aninterlayer dielectric (ILD) layer is formed on the first etch stoplayer. A second etch stop layer is formed on the ILD layer. A portion ofthe first etch stop layer, a portion of the ILD layer and a portion ofthe second etch stop layer are etched to form an opening on the firstportion, in which the remaining portion of the first etch stop layer,the remaining portion of the ILD layer and the remaining portion of thesecond etch stop layer form a sidewall of the opening. A protectivelayer is deposited on the sidewall and the epi-layer, in which theprotective layer is formed from oxide or nitride. A liner is formed onthe protective layer. A sputter etching operation is performed to removea portion of the protective layer and a portion of the liner on theepi-layer. The opening is cleaned using an SPM solution, in which theSPM solution includes H₂SO₄ and H₂O₂. A silicide cap is formed on theepi-layer. The opening is filled with a contact plug.

In accordance with alternative embodiments, the present disclosurediscloses a method for fabricating a semiconductor device. In thismethod, a substrate is provided. A dielectric layer is formed on thesubstrate. A portion of the dielectric layer is etched to form anopening, in which the opening has a bottom and a sidewall surroundingthe bottom. A protective layer is deposited on the sidewall and thebottom, in which the protective layer is formed from oxide or nitride. Aliner is formed on the protective layer. A sputter etching operation isperformed to remove the protective layer and the liner on the bottom.The opening is cleaned using an SPM solution, in which the SPM solutionincludes H₂SO₄ and H₂O₂.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A semiconductor device, comprising: a substratewith a first portion and a second portion adjacent to the first portion;an epi-layer disposed in the first portion; a first etch stop layerdisposed on the second portion; an interlayer dielectric (ILD) layerdisposed on the first etch stop layer; a second etch stop layer disposedon the ILD layer, wherein the first etch stop layer, the ILD layer andthe second etch stop layer form a sidewall surrounding the firstportion; a protective layer disposed on the sidewall, wherein theprotective layer is formed from oxide or nitride; a liner disposed onthe protective layer that enhances an adhesive effect between thesidewall and the liner, wherein the protective layer and the liner areformed from different materials; a silicide cap disposed on theepi-layer; and a contact plug disposed on the silicide cap andsurrounded by the liner.
 2. The semiconductor device of claim 1, whereinthe epi-layer is formed from silicon or silicon-germanium.
 3. Thesemiconductor device of claim 1, wherein the epi-layer is a source/drainregion.
 4. The semiconductor device of claim 1, further comprising ametal gate on the second portion of the substrate.
 5. The semiconductordevice of claim 1, wherein the protective layer is formed from siliconoxide or silicon nitride.
 6. The semiconductor device of claim 1,wherein the liner is formed from silicon nitride, silicon oxy-nitride,silicon carbide or silicon oxy-carbide.
 7. The semiconductor device ofclaim 1, wherein the silicide cap is formed from titanium silicide,nickel silicide, cobalt silicide, platinum silicide, palladium silicide,tungsten silicide, tantalum silicide or erbium silicide.
 8. Thesemiconductor device of claim 1, wherein the contact plug is formed fromaluminum (Al), tungsten (W), or copper (Cu).
 9. The semiconductor deviceof claim 1, further comprising an inter-metal dielectric layer disposedon the second etch stop layer.
 10. A semiconductor device, comprising: asubstrate with a first portion and two second portions sandwiching thefirst portion; an epi-layer disposed in the first portion; a silicidecap disposed on the epi-layer; a contact plug disposed on the silicidecap; a first etch stop layer disposed on the second portions andextending to the first portion; an interlayer dielectric (ILD) layerdisposed on the first etch stop layer and extending to the firstportion; a second etch stop layer disposed on the ILD layer andextending to the first portion, wherein the first etch stop layer, theILD layer and the second etch stop layer form a sidewall; a protectivelayer peripherally enclosed by the sidewall, wherein the protectivelayer is formed from oxide or nitride; and a liner peripherally enclosedby the protective layer that enhances an adhesive effect between thesidewall and the liner, wherein the protective layer and the liner areformed from different materials.
 11. The semiconductor device of claim10, wherein the epi-layer is a source/drain region.
 12. Thesemiconductor device of claim 10, further comprising: a metal gate onone of the second portions of the substrate; and an isolation featuredisposed in the other one of the second portions of the substrate. 13.The semiconductor device of claim 10, wherein the protective layer isformed from silicon oxide or silicon nitride.
 14. The semiconductordevice of claim 10, wherein the liner is formed from silicon nitride,silicon oxy-nitride, silicon carbide or silicon oxy-carbide.
 15. Thesemiconductor device of claim 10, further comprising an inter-metaldielectric layer disposed on the second etch stop layer.
 16. Asemiconductor device, comprising: a substrate with two first portionsand one second portion sandwiched by the first portions; an epi-layerdisposed in each of the first portions; a silicide cap disposed on theepi-layer; a contact plug disposed on the silicide cap; a first etchstop layer disposed on the second portion and extending to the firstportions; an interlayer dielectric (ILD) layer disposed on the firstetch stop layer and extending to the first portions; a second etch stoplayer disposed on the ILD layer and extending to the first portions,wherein the first etch stop layer, the ILD layer and the second etchstop layer form a sidewall on each of the first portions of thesubstrate; a protective layer peripherally enclosed by the sidewall,wherein the protective layer is formed from oxide or nitride; and aliner peripherally enclosed by the protective layer that enhances anadhesive effect between the sidewall and the liner, wherein theprotective layer and the liner are formed from different materials. 17.The semiconductor device of claim 16, wherein the epi-layer is asource/drain region.
 18. The semiconductor device of claim 16, furthercomprising a metal gate on the second portion of the substrate.
 19. Thesemiconductor device of claim 16, wherein the protective layer is formedfrom silicon oxide or silicon nitride.
 20. The semiconductor device ofclaim 16, wherein the liner is formed from silicon nitride, siliconoxy-nitride, silicon carbide or silicon oxy-carbide.